PARIS - September 29, 2010: Lamborghini is redefining the future of the
super sports car with a unique technology demonstrator. Boasting an
extremely lightweight construction thanks to advanced carbon-fiber
technology, the Lamborghini Sesto Elemento has an overall curb weight of
just 999 kilograms (2,202 lb) – including V10 power unit and
permanent all-wheel drive. This makes the Sesto Elemento a unique
demonstration of the technological expertise of Automobili Lamborghini.
Innovative carbon-fiber technologies are being used here for the first time
in an automotive application. As a 100 percent subsidiary of AUDI AG, the
Italian carmaker also benefits from the undisputed expertise of the German
manufacturer when it comes to lightweight construction.

With its amazing output of 570 hp, sensational power-to-weight ratio of
only 1.75 kilograms per hp and 0 to 100 km/h (0-62 mph) acceleration of
only 2.5 seconds, the Sesto Elemento guarantees unparalleled driving fun.
At the same time, fuel consumption also drops because of the extreme
lightweight engineering applied throughout.

The name of this technology demonstrator is derived from the periodic
table, where carbon is classified as the sixth element. Thus, the Sesto
Elemento demonstrates the worldwide leading expertise of Lamborghini in
carbon-fiber reinforced plastics (CFRP) technology. The super sports car
brand from Sant’Agata Bolognese is the only vehicle manufacturer in
the world to have mastered the complete CFRP process across a range of
technologies, from 3D design through simulation, validation, production and
testing – all in a state-of-the-art industrial process that stands
for the very highest quality standards.

Click PLAY to watch exclusive interview with Stephan Winkelmann, President and CEO of
Automobili Lamborghini

Lamborghini drives the technology development in its two research
centers the ACRC (Advanced Composite Research Center) and the ACSL
(Advanced Composite Structures Laboratory) through collaborations with
organizations such as Boeing, with the resulting technology secured under a
host of patents.

“The Lamborghini Sesto Elemento shows how the future of the super
sports car can look – extreme lightweight engineering, combined with
extreme performance results in extreme driving fun. We put all of our
technological competence into one stunning form to create the Sesto
Elemento,” comments Stephan Winkelmann, President and CEO of
Automobili Lamborghini. “It is our abilities in carbon-fiber
technology that have facilitated such a forward-thinking concept, and we of
course also benefit from the undisputed lightweight expertise of AUDI AG.
Systematic lightweight engineering is crucial for future super sports cars:
for the most dynamic performance, as well as for low emissions. We will
apply this technological advantage right across our model range. Every
future Lamborghini will be touched by the spirit of the Sesto
Elemento.”

Groundbreaking technology package

With the Sesto Elemento, Lamborghini’s R&D engineers have put
together a groundbreaking package. As a pure and radical concept, the Sesto
Elemento is the unique synthesis of an extremely low curb weight of less
than 1000 kilograms, enormous 570 hp output, the sensitive and prompt
responsiveness of the high-revving, naturally-aspirated V10 engine and the
superior traction and stability of permanent all-wheel drive – there
has never been a super sports car as thoroughbred as this. Sesto Elemento
delivers an unbelievable degree of driving fun, concentrated on absolutely
sensational dynamics.

Systematic use of carbon fiber

The basis is an extremely solid, stiff, safe and lightweight
carbon-fiber structur: the monocoque cell of the Sesto Elemento. The entire
front frame, the exterior panels and crash boxes are also made from CFRP.
The Sesto Elemento’s major suspension components and the rims are
made from carbon fiber. The tailpipes are made from Pyrosic, which is an
advanced glass-ceramic matrix composite, able to reach and stand very high
temperatures up to 900° celsius. Even the propeller shaft is made of
CFRP.

Amazing power-to-weight ratio

The Sesto Elemento demonstrates the outstanding expertise of Automobili
Lamborghini in all areas of carbon-fiber technology. Carbon composite
materials are a key technology for the automotive engineering of tomorrow,
especially for high-performance sports cars. These materials made from
carbon-fiber reinforced plastics combine the lowest weight with excellent
characteristics – they are extremely stiff and highly precise.
Lighter cars improve fuel consumption and CO2 emissions: above all,
however, it improves the power-to-weight ratio – the crucial factor
for a sports car – and thus the performance. A super sports car built
using CFRP accelerates faster, has outstanding handling and better
braking.

Extreme lightweight engineering delivers extreme performance

The Lamborghini Sesto Elemento offers the ultimate proof; thanks to its
sensational power-to-weight ratio of only 1.75 kilograms per hp, the
concept car delivers unparalleled performance. From a standing start, the
Sesto Elemento catapults itself to 100 km/h (62 mph) in a sensational 2.5
seconds. In the interests of completeness, it should also be mentioned that
the top speed is well over 300 km/h. What the figures cannot convey,
however, are the Sesto Elemento’s razor-sharp handling, its voracious
turn-in and its huge braking power. Extreme lightweight engineering and
extreme performance come together in the Sesto Elemento to create an
all-new dimension in super sports car driving.

Design:

Technology in a progressive form

Uncompromising dynamics from the very first glance: the design of the
Lamborghini Sesto Elemento displays the sensuality of high performance and
possesses the elegance of pure, unadulterated power. The Sesto Elemento
lifts the design DNA of the Lamborghini brand to a new level and integrates
the functional consistency of carbon-fiber technology into its design
language. A clear strength of the CFRP technology is the reduction and
integration of components – something that has been used to its full
extent in this innovative technology concept.

The hi-tech material is visible everywhere. The Sesto Elemento is
finished in a new, matt-shimmer clear coat, meaning that the CFRP structure
can be seen throughout. Yet the Sesto Elemento is not just black; during
the final stage of production the carbon fiber parts receive a newly
developed and patented coat. Nano-Technology makes it possible to add fine
crystals with a

red shimmer. Surfaces covered with this type of finish glow red and
deliver an outstanding effect. Further, the surface is particularly
robust.

Consistent in form and function

On a Lamborghini, every single line has a clear function; the two
vertical ribs at the front, for example, improve the stiffness of the
component and guide the cooling air directly to the radiator behind them
and to the brakes. This guarantees the thermal wellbeing of the components
even under the toughest race track conditions.

The cooling air flows through two red triangular openings in the hood
beneath the front windscreen and through large outlets in the side panels
behind the front wheels. Sharply cut headlamp units complete the front end.
Reduction is the name of the game here, too – alongside the bi-xenon
lamps, there are four LEDs in each unit. The low front end looks incredibly
dominant, with the partially double-lipped front spoiler pushed way out
front and distinctively formed air intakes.

Precise lines, sharp edges

The entire side profile is cut like a sharp wedge, with the power center
of the car unmistakably just in front of the rear axle. A distinctive
sideline starts at the front wheel arch, rises along the door towards the
rear and ends at the broad shoulders above the rear wheel. The triangle
– like the one around the door handle - is a recurring design theme,
defined by the precise contour edges in the Sesto Elemento’s CFRP
body. The points of the air outlet triangles in the hood are carried
through into lines along the roof.

The extremely wide sills form a connection between the air outlets
behind the front wheels and the large air inlets in front of the rear
wheels. These compartments house components such as the radiators for
cooling the engine and transmission oil. The rims have a five-spoke design
and are made entirely from carbon fiber. They offer a clear view of the
high-performance brakes with carbon-ceramic discs.

Perfect aerodynamics

The Sesto Elemento’s rear overhang is extremely short and, again,
defined by optimum aerodynamics. The generously dimensioned spoiler is
perfectly matched to the diffuser and a further air deflector in the
center, thus guaranteeing maximum downforce for extreme cornering speeds
and excellent high-speed directional stability. The Pyrosic tailpipes are
directed

upwards through the engine cover panel, which also incorporates ten
hexagonal openings and two air scoops behind the roof for delivering fresh
air to the V10 power plant.

Complex structures in one component

A major strength of carbon-fiber technology is that complex structures
can be integrated into one single component. This improves quality and
reduces weight. On the Lamborghini Sesto Elemento, the front and rear of
the body-shell are each manufactured in a single piece. Engineers call this
“cofango”, created by combining the Italian word
“cofano” (hood) with “parafango” (fender). The
large components are attached by using easily removable fasteners, in order
to have fast component disassembly. The “cofango” is also
reminiscent of an icon from the brand’s history: in 1966, the
legendary Lamborghini Miura was unique as a mid-engine super sports car
– and its rear cover, too, could be opened in one piece.

Interior – pared to the bone

The minimalist approach has also been applied to the interior, starting
with the seats. Lamborghini has dispensed completely with the conventional
seat frame. In fact, the whole internal structure is obtained and defined
directly from the Forged Composite tub, that on one side plays a functional
role and on the other side is the base for the optimally formed seat
cushions, upholstered in hi-tech fabric, which are affixed directly to the
carbon-fiber monocoque. The correct ergonomics are provided by the steering
wheel, which can be adjusted for height and reach, and by the pedals, which
can be electrically adjusted longitudinally. Of course, the designers of
Lamborghini Centro Stile also dispensed with interior trim in the classic
sense. The dominant visual feature throughout is the functional CFRP
material – on the floor and roof of the monocoque, on the doors and
also on the cockpit and center console. Even the electronic control unit
for the engine is mounted in plain sight – a very special kind of
hi-tech aesthetic. The triangular cut-out is also evident as a design
feature – wherever material can be removed in the interest of weight
reduction.

The controls are presented in a highly concentrated format. The
instruments provide information primarily on engine and road speed, as well
as all parameters relating to engine condition. Only three piezoelectric
buttons grace the center console – one to start the engine, one to
shift into reverse gear and another one for the lights.

Technology:

Ambitious target reached with ease

The Sant’Agata Bolognese engineers had set themselves a target
that was more than ambitious – despite the ten cylinders and 570 hp,
despite the exceptionally fast-shifting e.gear transmission and even
despite the permanent all-wheel drive, the Sesto Elemento still had to stay
below the 1,000 kilogram mark. And that target was achieved; at a curb
weight of 999 kilograms, each hp produced by the V10 power unit has to
accelerate only 1.75 kilograms – a sensational figure.

This was made possible by the systematic and intelligent use of
state-of-the-art carbon-fiber technologies. Lamborghini possesses extensive
experience in the field of lightweight engineering, gathered over many
years: something clearly demonstrated by the brand’s series
production vehicles. The current Gallardo LP 570-4 Superleggera has a dry
weight of only 1,340 kilograms, marking a competitive best in this category
of super sports cars. Compared with the already extremely lean Gallardo LP
560-4 Coupé, this represents a further reduction of 70 kilograms, resulting
largely from the use of carbon fiber in the body-shell, interior and
technical components.

Lamborghini engineers stuck firmly to this approach for the Sesto
Elemento. Its structure consists almost entirely of carbon fiber and is
built using the monocoque principle. Monocoque means that the
vehicle’s load-bearing structure is manufactured as a single shell,
with the physical properties of one component, and thus makes optimum use
of the extreme stiffness offered by CFRP materials. Formula 1 racing cars
have been built using CFRP monocoques for decades – and regularly
provide clear evidence of their collision safety. The monocoque in the
Sesto Elemento, however, is made using innovative Forged Composite
technology – the first time this has been done in an automobile. The
advantage of the Forged Composite is that the monocoque is obtained through
a one-shot process.

Carbon-fiber crash boxes

In the Lamborghini Sesto Elemento, the monocoque forms the complete
passenger cell. Connected to it are the front subframe - incorporating the
suspension points - and the crash boxes, both also made using specialized
carbon-fiber technologies. The extreme stiffness of this assembly
guarantees not only a very high level of safety, but also unparalleled
handling precision. The rear subframe with the engine mount and rear
axle

suspension points is made from aluminum – another lightweight
material with which Lamborghini has a great deal of experience.

An important element in optimum construction using CFRP technology is
the maximum integration of functions. Thus, the body-shell exterior is made
up only of the roof section, which is part of the monocoque, the two
“cofango” covers front and rear with integrated aerodynamic
components and the doors. Each door consists of only two elements, the
exterior skin and the interior cladding, both of which are also permanently
bonded to create one component.

Carbon fiber even in the suspension

The suspension and the area around the engine have also been optimized
with lightweight engineering. Alongside aluminum components, there are also
carbon-fiber control arms: innovative Forged Composite technology is also
well-suited to this kind of high-load part. These components are around 30
percent lighter than comparable aluminum parts. The propeller shaft is also
made of CFRP by using Wrapping technology. This solution allowed the
Lamborghini engineers to get rid of the central joint, bringing an
important weight saving. The rims are also made from CFRP, while the brake
discs are from carbon-ceramic composite material. A similar composite
material is used for the tailpipes on the exhaust system – the
compound of ceramic powder and synthetic resin makes this carbon material
extremely heat resistant. A large number of screw fastenings feature a
special titanium alloy and joining technology from the aviation sector.

Based on the form, function and operational demands of the individual
Sesto Elemento components, engineers from Lamborghini’s R&D selected
largely from three CFRP manufacturing techniques within their technology
tool kit:

Forged Composite: Here, materials with short carbon fibers are hot
pressed in a mould. The process facilitates complex structures and is used
for parts such as the underside of the monocoque and the suspension
arms.

Prepreg: The carbon-fiber mats are soaked in a thermoset liquid resin.
They are pressed in moulds and cured in an oven under heat and pressure.
Prepreg components have a very good surface finish and are therefore the
preferred choice for use in visible areas.

Braiding: This is a method to manufacture composite filament derived
from the textile industry. Each thread is diagonally intertwined on
different levels.

Drive:

Concentrated power and amazing sound

The fascinating heart of the Lamborghini Sesto Elemento is familiar from
the Gallardo LP 570-4 Superleggera. In the Sesto Elemento too, the V10 unit
is mounted “longitudinale posteriore” – longitudinally
behind the driver. The 570 hp output equals 419 kW, all of which is
available at 8,000 r/min. The pulling power is just as impressive –
with the torque curve peaking at 540 Nm and 6,500 r/min.

The V10 offers 5,204 cm3 of displacement, delivering a specific output
of 80.5 kW (109.6 hp) per liter of displacement. The highlights of this
long-stroke engine with an aluminum crankcase include dry sump lubrication
and a cylinder angle of 90 degrees. Both solutions are an integral part of
the lightweight engineering approach, as well as serving to lower the
center of gravity and thus tighten the handling characteristics. Ideal
combustion chamber fill comes courtesy of a switch-over induction system
and continually variable, chain-driven camshafts.

Best traction with all-wheel drive

The Sesto Elemento is equipped with the e.gear transmission, controlled
in race car fashion via shift paddles mounted on the steering wheel. The
automated system with electronic management shifts smoothly through its six
gears much faster than a human being would be able to.

Every single kilometer in the Sesto Elemento is sheer fascination
– due in part to the relentless traction delivered under practically
all conditions. This is largely attributable to the permanent all-wheel
drive system. It incorporates a central viscous coupling and a self-locking
differential for the rear wheels with 45 percent lock. Thanks to this
superior traction, Lamborghini drivers can accelerate earlier out of a
curve than those in rear-wheel drive cars.

Competence: New development center for carbon-fiber technology

Lamborghini possesses many years of experience with carbon-fiber
reinforced materials. As far back as 1983, it produced the first prototype
CFRP chassis for the Countach, with the first series production parts
appearing in 1985. The current Lamborghini Murciélago is made largely from
CFRP – its body-in-white contains 93 kilograms of carbon-fiber
materials. The

engine cover panel of the Gallardo Spyder is one of the largest CFRP
components with class A surface quality in the automotive world.

The company is now working steadily to expand its worldwide leading
position. The new Advanced Composites Research Center (ACRC) at the company
headquarter in Sant’Agata Bolognese is working on innovative
construction and production methods for carbon-fiber elements in automobile
design.

The Advanced Composite Research Center in Sant’Agata Bolognese
secures leading-edge research on innovative materials and production
methods for carbon fiber elements for small production volumes. Here, over
30 experts develop vehicle components of all shapes and sizes. They build
prototypes and the associated production tools while developing optimized
production technologies. Sophisticated systems largely developed in-house
allow extremely high precision levels as engineers simulate manufacturing
processes as well as carry out crash tests on complex carbon-fiber
structures. Thanks to the extensively patented “RTM Lambo”
process, Lamborghini can use minimal pressure and relatively low
temperatures to manufacture carbon-fiber components to the highest levels
of quality, precision and surface finish, from small parts to complex
vehicle structures. Further benefits include higher process speeds, lower
costs, and extremely light tooling.

The Lamborghini Advanced Composite Structures Laboratory (ACSL) at the
University of Washington uses experimental tests to define the mechanical
behavior of the different materials and technologies using methodology from
the aviation industry. The team of research engineers in Seattle works with
very specific instruments and methods in close cooperation with the R&D
headquarters and the ACRC in Sant’Agata Bolognese.